Capacitor-circuit board interface for welding system components

TECHNICAL FIELD

p-0002The present disclosure relates to welding system components, and more specifically, to an interface between a capacitor and circuit board for a component of a welding system.

BACKGROUND

p-0003Welding is an important process in the manufacture and construction of various products and structures. Applications for welding are widespread and used throughout the world including, for example, the construction and repair of ships, buildings, bridges, vehicles, and pipe lines, to name a few. Welding is performed in a variety of locations, such as in a factory with a fixed welding operation or on site with a portable welder.

p-0004In automated or mechanized welding a user/operator (i.e. welder) programs or instructs welding equipment to make a weld. For example, in Submerged Arc Welding (SAW) a consumable solid or tubular (flux cored) electrode may be continuously fed into a molten weld or arc zone that is protected from atmospheric contamination by being “submerged” under flux such as a blanket of granular fusible material consisting of lime, silica, manganese oxide, calcium fluoride, or other suitable compounds. Generally, when molten, the flux becomes conductive, and provides a current path between the electrode and the work. A thick layer of flux completely covering the molten metal may thus prevent spatter and sparks as well as suppress the intense ultraviolet radiation and fumes that may be a part of the arc welding process. In such a process, currents ranging from 300 to 2000 A may be utilized. Additionally, currents of up to 5000 A may be used with multiple arcs. Single or multiple electrode wire variations of the process exist. Also, DC or AC power can be used, and/or combinations of DC and AC in multiple electrode systems. Generally, constant voltage welding power supplies are most commonly used; however, constant current systems in combination with a voltage sensing wire-feeder are also available.

p-0005In manual or semi-automated welding a user/operator (i.e. welder) directs welding equipment to make a weld. For example, in electric arc welding the welder may manually position a welding rod or welding wire and produce a heat generating arc at a weld location. In this type of welding, the spacing of the electrode from the weld location is related to the arc produced and to the achievement of optimum melting/fusing of the base and welding rod or wire metals. The quality of such a weld is often directly dependant upon the skill of the welder.

p-0006Submerged Arc Welding and Electric Arc Welding, among other types of welding, may occur in a variety of environments. As such, it is generally desirable to protect the components of welding systems for use in a variety of conditions.

p-0007In the past, various methods and devices have been used to protect the components of welding systems. For example, there has been a desire to encapsulate the circuit boards of welding components to protect them from their environment, for example with a dip-and-cure epoxy coat. However, encapsulation of these boards for environmental protection is difficult due to the need of capacitors to be mounted directly to the board. Any area for mounting of a capacitor requires damming prior to encapsulation in order to prevent encapsulation of these areas.

p-0008Additionally, connections of capacitors to circuit boards are typically high temperature connections due to the nature of the materials of capacitors. This heat is typically displaced into the circuit board and thus raises the temperature of the board and other components mounted to the board. It is desired to minimize this heat transfer from the capacitor connections to the board.

SUMMARY OF THE INVENTION

p-0009This invention relates to welding system components and an interface for capacitors and circuit boards of such components.

p-0010A welding system component includes a circuit board for the welding system component. An interface has a main riser portion with a fastener passageway formed therethrough. The interface has an extension portion with a terminal passageway formed therethrough. The extension portion is electrically connected to the circuit board with a terminal disposed in the terminal passageway. The extension portion is spaced away from a surface of the circuit board. A capacitor is electrically connected to the main riser portion with a fastener disposed in the fastener passageway.

p-0011Various aspects will become apparent to those skilled in the art from the following detailed description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0012<figref idrefs="DRAWINGS">FIG. 1</figref> is a schematic view of a welding environment;

p-0013<figref idrefs="DRAWINGS">FIG. 2</figref> is a perspective view of the welder of <figref idrefs="DRAWINGS">FIG. 1</figref>;

p-0014<figref idrefs="DRAWINGS">FIG. 3</figref> is an enlarged view of a portion of the welder of <figref idrefs="DRAWINGS">FIG. 2</figref> shown with the access panel shown partially cut away;

p-0015<figref idrefs="DRAWINGS">FIG. 4</figref><i>a </i>is a top view of a portion of the circuit board assembly shown in <figref idrefs="DRAWINGS">FIG. 3</figref>;

p-0016<figref idrefs="DRAWINGS">FIG. 4</figref><i>b </i>is a front view of the portion of the circuit board assembly shown in <figref idrefs="DRAWINGS">FIG. 4</figref><i>a; </i>

p-0017<figref idrefs="DRAWINGS">FIG. 5</figref> is an enlarged side view of a portion of the circuit board assembly of <figref idrefs="DRAWINGS">FIG. 4</figref><i>b; </i>

p-0018<figref idrefs="DRAWINGS">FIG. 6</figref> is a perspective view of the interface of <figref idrefs="DRAWINGS">FIG. 5</figref>;

p-0019<figref idrefs="DRAWINGS">FIG. 7</figref> is a top view of the interface of <figref idrefs="DRAWINGS">FIG. 6</figref>;

p-0020<figref idrefs="DRAWINGS">FIG. 8</figref> is a side view of the interface of <figref idrefs="DRAWINGS">FIG. 6</figref>; and

p-0021<figref idrefs="DRAWINGS">FIG. 9</figref> is a front view of the interface of <figref idrefs="DRAWINGS">FIG. 6</figref>.

DETAILED DESCRIPTION

p-0022The best mode for carrying out the invention will be described for the best mode known to the applicant at the time. The examples and figures are illustrative only and not meant to limit the invention, as measured by the scope and spirit of the claims.

p-0023Referring now to the drawings, there is illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref> welding environment <b>10</b>. Welding environment <b>10</b> includes welding system <b>12</b>, and work piece <b>14</b>. Welding system <b>12</b> includes welding gun <b>16</b> with a wire feed passage connected to a wire feeder (not shown) and with an electrode connected to welding power supply <b>18</b>. Exemplary welding environment <b>10</b> also includes wire feed controller <b>20</b> and power controller <b>22</b> with user interface <b>24</b> for programming and monitoring system <b>12</b>. welding environment may also, for example, include a stick electrode holder, TIG torch or other apparatus for use with electric arc welding or other equipment as appropriate for other types of welding.

p-0024Work piece <b>14</b> and proximate space generally defines welding work area <b>26</b> where the welding gun may be used to form a weld. Various types of exemplary welding, including Submerged Arc Welding (SAW), Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW) e.g. MIG melding, and Gas Tungsten Arc Welding (GTAW) e.g. TIG welding, may be conducted in the welding environment.

p-0025Welding system <b>12</b> includes welding equipment, such as welding power supply <b>18</b>, for generating a welding current and voltage, a welding control system for controlling the welding current and voltage, and a monitoring system for monitoring the welding current and voltage. The monitoring system may also monitor a variety of other operating parameters, such as but not limited to, welding wire feed speed, amount of welding wire remaining, any type of welding feedback desired by the operator, and any other desired operating parameters.

p-0026In one embodiment, as best shown in <figref idrefs="DRAWINGS">FIGS. 2 and 3</figref>, welding power supply <b>18</b> is illustrated for line powered welding, e.g. welding supplied with electric power from a power grid. However it must be understood that welding power supply <b>18</b> may be for other types of welding, such as engine welding, e.g. with a motor-generator. Welding power supply <b>18</b> includes cabinet <b>28</b> that is suitable to house equipment that supplies power to output leads for welding.

p-0027Cabinet <b>28</b> includes base <b>30</b>, an access panel <b>32</b>, control panel <b>34</b>, side panels <b>36</b> and cover <b>38</b>.

p-0028Access panel <b>32</b> may include optional air louvers. Access panel <b>32</b> may provide access to an optional fan(s), such as an impeller or blower disposed in cabinet <b>28</b>.

p-0029Welding power supply <b>18</b> or user interface may optionally include a number of input devices, such as a knob, slides, switches, buttons or other digital or analog controls, for example to adjust the output of the welder or perform other control operations, e.g. welding mode, arc control, etc, and may be mounted on control panel <b>34</b>. Additionally, display devices may also fastened to welding power supply <b>18</b> or user interface for display of operation parameters of welding system <b>12</b>, as well as optional gauges. The input devices may be associated with a control board with or without an optional chopper.

p-0030As best shown in <figref idrefs="DRAWINGS">FIG. 3</figref>, welding power supply <b>18</b> also includes various electronic components <b>40</b> as desired, such as switches, resistors, rectifiers, diodes, power control boards, and capacitors <b>42</b>. As desired, a variety of these components maybe mounted within a compartment in cabinet <b>28</b> adjacent control panel <b>34</b>. As such, in the illustrated example, they are accessible through a front opening associated with control panel <b>34</b>.

p-0031An exemplary circuit board assembly <b>44</b> for association with capacitors <b>42</b> is shown in <figref idrefs="DRAWINGS">FIGS. 4</figref><i>a </i>and <b>4</b><i>b</i>. Circuit board assembly <b>44</b> includes circuit board <b>46</b> that has solder side “S” and component side C. Circuit board assembly <b>44</b> may optionally include a number of associated electrical components <b>40</b> electrically connected to circuit board <b>46</b>. Additionally, an optional heat sink assembly (not shown) may be thermally connected to circuit board <b>46</b>.

p-0032As best shown in <figref idrefs="DRAWINGS">FIG. 5</figref>, capacitor <b>42</b> is connected to circuit board <b>46</b> by at least one interface <b>70</b>. circuit board assembly <b>44</b> includes a pair of mounting terminals (one shown); positive mounting terminal <b>72</b> and a negative mounting terminal (not shown) each connected to respective interface <b>70</b>. <figref idrefs="DRAWINGS">FIGS. 5-9</figref> are described with regard to positive mounting terminal <b>72</b>. It must be understood however, that the connection to an arrangement of the negative mounting terminal (not shown) and respective interface <b>70</b> a similar to that of positive mounting terminal <b>72</b> as described below, except as otherwise noted.

p-0033As best shown in <figref idrefs="DRAWINGS">FIGS. 5-9</figref>, interface <b>70</b> includes main riser portion <b>74</b> and an extension portion <b>76</b> which generally extends a distance in a direction that is substantially normal to the longitudinal direction of main riser portion <b>74</b>, although such is not required. Exemplary interface <b>70</b> is machined from a single piece of copper. However, it must be understood that interface <b>70</b> may be formed from any other suitable material, such as copper alloy, aluminum, aluminum alloy or any other material suitable to support capacitor <b>42</b> and form an electrically conductive path between circuit board <b>46</b> and capacitor <b>42</b>.

p-0034Interface <b>70</b> may act as a heat sink and reduce heat from circuit board <b>46</b> and/or capacitor <b>42</b>. This tends to protect circuit board <b>46</b> and allow components <b>40</b> connected there to run cooler, as compared to when capacitor <b>42</b> is connected directly to circuit board <b>46</b>. As a result, a plurality of capacitors <b>42</b> may be bussed together, as illustrated in <figref idrefs="DRAWINGS">FIGS. 4</figref><i>a </i>and <b>4</b><i>b</i>, and/or be placed closer together on circuit board <b>46</b> than otherwise would be the case. Additionally, this configuration minimizes inductance in during the setup of circuit board assembly <b>44</b>. It is noted that in at least one configuration circuit board <b>46</b> may include a thick copper substrate upon which other layers and components are placed.

p-0035Main riser portion <b>74</b> includes fastener passageway <b>78</b> formed therethrough. Extension portion <b>76</b> extends from one end of main riser portion <b>74</b> and includes terminal passageway <b>80</b> formed there through.

p-0036Fastener passageway <b>78</b> is formed such that fastener <b>82</b>, such as a bolt or other fastening device, may be disposed therein to fasten interface <b>70</b> to capacitor <b>42</b>, either directly or with an optional component mount <b>84</b>, which, for example, may be made of a different material than interface <b>70</b>. Interface <b>70</b> may optionally be fastened to capacitor <b>42</b> by clips, screws, pins or any other mechanism suitable to electrically connect interface <b>70</b> to capacitor <b>42</b>. Further, as illustrated, fastener <b>82</b> provides an optional first positive lead connection <b>86</b> such that one or more leads may be mounted to the top of interface <b>70</b> to electrically connect to board <b>46</b> and/or capacitor <b>42</b>. Additionally or alternatively an optional washer may be disposed between the end of fastener <b>82</b> and the surface of interface <b>70</b>.

p-0037Terminal passageway <b>80</b> is formed such that terminal <b>72</b> may be disposed therein to mount circuit board <b>46</b> to interface <b>70</b> and electrically connect capacitor <b>42</b> to circuit board <b>46</b>. Terminal <b>72</b> may be fastened to interface <b>70</b> by a bolt, clip, screw, pin or any other mechanism suitable to electrically connect circuit board <b>46</b> to interface <b>70</b>. Further, as illustrated, the connection to terminal <b>72</b> may provide an optional second positive lead connection <b>88</b> such that one or more leads may be mounted to the top of interface <b>70</b> to electrically connect to circuit board <b>46</b> and/or capacitor <b>42</b>. It must be understood that interface <b>70</b> associated with the negative mounting terminal (not shown) may also have similar first and second negative lead connections such that one or more leads may be mounted to the top of interface <b>70</b> associated with the negative mounting terminal (not shown) to electrically connect to board <b>46</b> and/or capacitor <b>42</b>. Additionally or alternatively an optional washer may be disposed between the end of terminal <b>72</b> and the surface of interface <b>70</b>.

p-0038As illustrated in <figref idrefs="DRAWINGS">FIG. 5</figref>, in the case of positive mounting terminal <b>72</b>, current “I” flow in a direction from capacitor <b>42</b> along main riser portion <b>74</b> and/or fastener <b>82</b>, through extension portion <b>76</b> and to positive mounting terminal <b>72</b>. In the case of the negative mounting terminal (not shown) current will flow in a direction exactly opposite to that for positive mounting terminal <b>72</b>. In the illustrated embodiment current flow “I” in positive mounting terminal <b>72</b> is between extension portion <b>76</b> and to the surface of circuit board <b>46</b>.

p-0039During assembly, terminal <b>72</b> may be connected to component side “C” of circuit board <b>46</b>, along with any desired components <b>40</b>. After terminal <b>72</b> is connected to circuit board <b>46</b>, main riser portion <b>74</b> extends away from the surface of circuit board <b>46</b> with extension portion <b>76</b> being elevated off the surface of circuit board <b>46</b>. In the illustrated embodiment main riser portion <b>74</b> extends generally orthogonally to the surface of circuit board <b>46</b> with extension portion <b>76</b> extending generally parallel to the surface of circuit board <b>46</b>.

p-0040Circuit board <b>46</b> may optionally be covered with encapsulation material <b>90</b>. Subsequently, capacitor <b>42</b> and interface <b>70</b> may then be connected to circuit board <b>46</b>.

p-0041Alternatively, portions of the circuit board <b>46</b> may be dammed as desired, circuit board <b>46</b> covered with encapsulation material <b>90</b> and terminal <b>72</b> and other components <b>66</b> then connected, with capacitor <b>42</b> and interface <b>70</b>. Further in the alternative, terminal <b>72</b>, and thus interface <b>70</b>, may be mounted on solder side “S” of circuit board <b>46</b> such that capacitor <b>42</b> may be positioned on solder side “S” and thus allow a connection to be made to component side “C” at a minimal distance.

p-0042Once interface <b>70</b> is connected to circuit board <b>46</b>, main riser portion <b>74</b> extends away from the surface of circuit board <b>46</b> with extension portion <b>76</b> being elevated off the surface of circuit board <b>46</b>. In the illustrated embodiment main riser portion <b>74</b> extends generally orthogonally to the surface of circuit board <b>46</b> with extension portion <b>76</b> extending generally parallel to the surface of circuit board <b>46</b>.

p-0043It is noted that in one assembly the connections to terminal <b>72</b> may be made with greater force than the connections to fastener <b>82</b>. For example, fastener <b>82</b> may be tightened with 10 to 15 inch-pounds of torque, while the terminal may be tightened with 50 inch-pounds of torque or more.

p-0044As well as during normal operation, interface <b>70</b> may reduce unwanted heat from being absorbed circuit board <b>46</b> during assembly. Main riser portion <b>74</b> and extension portion <b>76</b> disrupt the heat from capacitor <b>42</b> from being absorbed into circuit board <b>46</b>. Additionally, as a plurality of capacitors <b>42</b> may be bused together and be placed relatively closely together on circuit board <b>46</b>, it is contemplated that the plurality of interfaces <b>70</b> may be mounted relatively closely together during assembly.

p-0045While principles and modes of operation have been explained and illustrated with regard to particular embodiments, it must be understood, however, that this may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.